Wallboard construction



NOV. 19, B. B REGER 2,222,572

t WALLBOARD CONSTRUCTION Filed July 15, 1957 2 Sheets-Sheet 1 aww/Mio@ BL/ Hf B. Reger Nov. 19, 19. B, BREGER wALLBoARD CONSTRUCTION Filed July l5, 1937 2 Sheets-Sheet 2 p. E `fr u E Patented Nov. 19, 1940 UNITED 'STATES PATENT oF- Fics .The Deco-Board Corporation,

W. Va.,

Parkersburg,

Application July 15, 1937, Serial No. 153,819

, 3 Claims. (Cl. 20'15) This invention relates to improvements in wallboard construction and more particularly to 'wallboard units madefrom corrugated paper.

' One of theobjects of the present invention is to provide an improved wallboard made of inexpensive material yet strong and durable in construction.l A further object is to convert ordinary corrugated board asit is known into Iwallboard units by cutting, trimming and creas- -l() ing standard size sheets into fforms suitable for immediate application.y A further object is to provide an improved wall insulating board of the above general character which maybe easily and quickly applied,iand which when finished will be free from unsightly nail heads or lexposed fastening' means, seams or joints. A further object is to provide a wallboard unit which may be associated with other units at any angle or in any position and when so positioned will not expose any markings either as to securing means or joints. A furtheryobjectis to provide an improved fastening device for securing the units in placeto the joists or other points of the building. A `further object is to provide an improved insulating unit which may be packed unique relation of the members, and in the relative proportioning and disposition thereof, all as more completely outlined herein.

- To enable others skilled in the art to fully `com' 4 prehend the underlying features of the invention,

that they may embody the same vby the several l modications in structure and `relation contem` plated bythe invention, drawings .depicting preferred forms have been annexed as part of this disclosure, and inA such drawings like characters of reference denote corresponding parts throughout the views, in which- Figure -1 is 'a' fragmentary perspective viewy i of one form of a'complete unit shown mits folded position and having both overlap and underiap edges. l Figure 2 is a similar view of the same unit as it is beingv unfolded with a portion of adjacent I board fitted thereto. o 4 Figure 3 is adetail perspective view of an imconsists in the feaproved fastening means holding a part in place. Figure 4 is adetail perspective view showing manner of securing the adjacent edges of two boards, where no Yjunderlap is used.

Figure 5l is a detail view showing the decora- 5 tive surface of two finished boards or one board cut to iit a ceiling and wall corner.

Figure 6 is a detailperspective `view showing the board applied to an inwardly extending angle. 10 Fig-ure 7 is a similar view showing the board as applied to an outwardly extending or projecting angle.'

Figure. 8 is a detail elevational view showing the manner in which two or more boards may l5 be -joined with respect to studs.

Figure 9 is a detail sectional plan view of the parts shown in Figure.

Figure 10 is a detail perspective View showing the manner in which portions of the board may 20 `be removed in order to provide additional overlaps as when and where necessary.

' Figure 11 is a detail of a multiple-ply board. Referring now to the drawings in detail and more particularly to Figure l'where the unit is 25 shown in folded position, this unit is shown in its simplest form, that is it is made from a standard size single sheet of corrugated board, comprising a sheet Il of corrugated paper which is interposed between two sheets of relatively stiff 30 paper I2 and I3 but a plurality of these sheets may be, secured together as shown inFigure l1 l if desired. The relative thickness of the several sheets Amay also be varied as desired, but the board such as used in making ordinary packing 35 boxesl of corrugated paper has been found satisfactory. These sheets'are preferably'cut to a width adapted to accominodate the tance bef 'j tween three studs of a building Figure 8. As .is well known to those familiar with buildings, these 40 studs areusually spaced either 16 or 24 inches apart; consequently the boards are usually made/ in units of r32 or 48 inches in width and of a suitablev height. This height may vary say from 6 to.f 12 feet. I A

Onel edge of the board as shown in Figure 1 I4 the purpose of which will be more fully hereinafter explained. This overlap usually consists of but a single thickness of paper. The back of 50 the board and alonga line substantially parallel n but slightly spaced to one side ofthe middle is cut, the cuty extending through the rear layer I2 and thecorrugated sheethlel as clearly shown in both' Figures 1 and 2, w reupo'n the board 55 Vis preferably provided with an overlap portion -A is` folded over upon itself upon line Il, Figure 2, until the extreme outer edge of the overlap Il Ais coincident with the extreme edge It lof the other or underlap part.

5 It will thus be seen that when one part is folded over upon the other, as clearly shown in Figure 1, this overlap I4 is adjacent the lower portion of .the unit whereby the folded unit may be packed with numerous other units in bundles of 10 or 12 as desired and shipped without dangerl of mutilating the overlap. Further.y the outside I3 or decorative finish is on the inside of the folded unit and consequently protected from dirt and damage.

Referring now to Figures 3 and 4, I1 represents an ordinary studding of a building and to which the unit is adapted to be secured. Only one upper corner of the unit is herein illustrated which includes the sheets |2 and I3 and interposed corrugated sheet I I as referred to in connection with Figure 1. The overlap It is shown notonly turned back to permit th'e fastening but is normally unsecured to the corrugated sheet I| for a distance substantially equal tc the width of the overlap, i. e. about V4". This is subsequently secured by adhesive either applied then or previously if of the water soluble kind.

'Ihe holding means illustrated in this view comprises a relatively small flat device I8 preferably 3.9 of sheet metal having a somewhat pointed end 20 adapted to ilt between the corrugations with its opposite end out away or provided with a hole adapted to receive a nail as indicated at 2|. It has been found that these holding devices Il may be slid into one of the recesses of the` corrugated board or over the corrugated board as shown whereupon the nail 2l is driven into the joists thus holding the board firmly against the studding I1. 'Ihis holding device being of flat sheet 40 metal permits the next adjacent board as shown in Figure 9 to be tacked directly to the studding or if preferred the unit may be placed adjacent the studding and the single nail 2| holds both of the adjacent edg of the sheets in fixed position. It is particu] rly useful in securing the sheet to the intermediate joist as shown at the right or left in Figures 8 and 9.

It may,.however, be more desirable to omit this holding device and merely drive nails 2| through the adjacent concealed edges of the two units as shown in Figure 4. 'Ihe overlap 'il being free from the right hand board, the left handboard may be cut away at the edge as shown at the right of Figure 2 if desired, whereby the overlap.

5.5 will lay flush in the cut away or underlap portion and cover the nail heads thus making a smooth overlap. It is, of course, desirable to use some 4 simple form of adhesive for securing the overlap in position on the lower board which will not 4e0 smear or dlscolor the surface markings of the board as applied.

. In Figure 5 there is shown an upper wall and ceiling corner illustrating how one board may be cut and folded or whereby any two boards may '65 be placedadjacent each other at any angle without showing the line of demarcation between the boards. The irregular mottled or unmatching design on the outer surface is especially important when used in such relation.

`70 In Figure 6 there is illustrated the manner in which the unitmay be folded to take care of a reentrant angle in the wall to be covered. that is, the inwardly projecting angle atthe corner of a room, for example. Wherever this angle occurs gi with respect to the positioned unit it is 'only necessary to take a sharp knife and cut through the rear wall I2 and the corrugated sheet but not through the outer or decorative sheet I3. This permits the outer sheet surfaces to be moved relatively towards each other to any angle with- 5 out breaking the finished surface I3 thereby to accommodate the unit -to the reentra'nt angle without exposing any demarcation at the juncture or 'detracting from the insulating qualities of the board. i-

In Figure 7 the unit is shown as being applied `to a projecting angle.4 that is the studding i'I projectsoutwardly into the room as where an L exists. Here the unit is applied inthe same manner as in Figure 6 except that a rear surface l5 |2 is grooved as by a V-shaped roller, for example, whereby the unit may be folded backwardly about th stud as clearly shown.

Referring to Figures 8 and 9, there is illustrated conventionally three adjacent studding I1 which 20 may be assumed to be each 16 inches apart and the units A and B are each of a width to ac' commodate the distance between the extreme right and the extreme left studding but for the purpose ofy `illustration only the two adjacent 25 halves of the units A and B are shown. Thus we have the unit A provided with a relatively thick underlap edge indicated at 23 while the adjacent edge of the unit B vis provided with the single thickness overlap' i4. 'I'he securing may 30 be either by nails 2| or clips I8, as at the right, either of which would be covered by means of the overlap I4 as shown or joint |5.-'Figure 2.` The adjacent or outside studding I1 merely permit the application of the units thereto and the secur-y 35 ing thereof to prevent breaking. Here the clip IB wouldbe especiallyuseful. In otherwwords, the extreme right portion (not shown), of the unit B is secured and the illustrated half B bent back to permit the driving in of the nail or the apr 40 plication of the holding clip I8 as illustrated. This holding device as here applied is attached by means of the nail 2| whereupon the left hand side as illustrated of the unit B is swung inwardly to position against the middle studding |'I and its- 45 securing means such as nails 2| are driven home after turning back the overlap Il. The next step is to apply the right hand portion of the unit A which may be done by driving its securing means 2I into the underlap portion and then its middle 50 to the left studding as shown whereupon the overlap I4 is adhesively secured in position, either by the application of adhesive or the moistening of a water soluble adhesivepreviously applied on the underlap or-underside of the overlap. Thus we have asubstantially unitary appearing nished wall free from any exposed nail heads or fastening devices.

In Figure 10 there is illustrated the'manner in whicha portion ofany unit may be further cut vqu) to provide an overlap at any place where desired. For'instance, a board or unit having the inner sheet I2, the outer sheet I3 and the interposed corrugated sheet as beforelis just cut along any line as for example line 2l extending thro'ugh 65 the sheet i2 and the corrugated sheet il whereupon these two parts may be stripped clear of the sheet I3 by a' simple downward pull.

If, however, the overlap is to take place on the upper edge of the unit as when mounting one above the other or tting to a wall-ceiling corner, Figure 5, then "the cut is made along the line 25 in the manner previously described and the strip withdrawn along this line as clearly shown at the top of Figure 10. This feature is especially advantageous when it is desired to insulate both the walls and ceiling of a room without the unsightly appearance of unmatchedv design and exposed fasteners. l

As thus seen, the present invention provides a simple and practical unit of wallboard construction which may be compactly folded for shipment with one or more other units as desired and with the assurance that the package will not suffer unnecessary damage during transportation. The overlap which is highly desirable primarily for the purpose of concealing otherwise exposed fastening means is protected by the folding portion of the wallboard. 'Ihe improved fastening device permits the use of a single means for securing the adjacent edges of two units with a single nail or it will permit the securing of the middle of the board adjacent the intermediate stud thereby to prevent a distortionof the board as may otherwise occur. The improved surface design of the board permits the sheet to be applied in units or a unit cut and folded with lthe assurance that no noticeable line of demarcation between the units or parts is visible as has been an objectionable feature in units of this character heretofore.

It is thusseen that the present invention contemplates an improved insulating wallboard accomplishing, among others, all of the objects and advantages herein set forth.

Without further analysis the foregoing will so fully reveal the gist of the invention that others can by applying current knowledge readily adapt it for various applications without omitting certain features that4 from the standpoint of the prior art fairly constitute essential character-lstics of the generic or specific aspects of this invention, and therefore such adaptations should and are intended to be comprehended within the 4U meaning and range of equivalency of the following claims.

I claim as my invention:

1. A wallboard unit comprising a sheet of corrugated paper between two relatively stiff sheets having along one edge an overlap formed by lextending one of the stiff sheets beyond the -corrugated paper, said overlap being unsecured to its corrugated sheet for a depth substantially equal to that of the extending overlap, said unit being folded back upon itself along a line slightly to one side of the longitudinal center line whereby when folded the overlap willbe protected against injury in transport by the portion of the board not provided with overlap.

2. A wallboard unit comprising a sheet of corrugated paper between two relatively stiff sheets having along one edge an overlap formed by extending one of the stiff sheets beyond the corrugated paper, said unit being folded back upon itself along aline slightly to one side of the longitudinal center line whereby when folded the overlap will be protected against injury in transport by the portion of the board not provided with overlap, said board having a decorative surface of irregular design whereby any two units may be placed edge 'to edge and eliminate the line separating any two units.

3. A multi-layer wallboard unit, the outer layer of which is adapted to form an overlap along one edge of the unit, said unit having a cut through the rear layer and spaced from the edge of the unit a distance substantially equal to the width of the overlap at the opposite edge whereby said rear layer may be stripped from the front layer.

to provide a free edge adapted to overlap the adjacent edge of another unit, and a single fastening means cooperating with the rear layer beneath the stripped overlap adapted to secure that unit and an adjacent unit to a stu'dding or the like.

BURT B. REGER. 

